EP3479712B1 - Thermal liner for protective garments - Google Patents
Thermal liner for protective garments Download PDFInfo
- Publication number
- EP3479712B1 EP3479712B1 EP18201602.2A EP18201602A EP3479712B1 EP 3479712 B1 EP3479712 B1 EP 3479712B1 EP 18201602 A EP18201602 A EP 18201602A EP 3479712 B1 EP3479712 B1 EP 3479712B1
- Authority
- EP
- European Patent Office
- Prior art keywords
- nonwoven
- gsm
- aramid
- thermal liner
- fiber
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Active
Links
- 230000001681 protective effect Effects 0.000 title claims description 23
- 239000000835 fiber Substances 0.000 claims description 43
- 239000004693 Polybenzimidazole Substances 0.000 claims description 32
- 239000012210 heat-resistant fiber Substances 0.000 claims description 10
- 239000004744 fabric Substances 0.000 claims description 8
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- 229920006231 aramid fiber Polymers 0.000 claims description 5
- 239000004745 nonwoven fabric Substances 0.000 claims description 4
- 229920006376 polybenzimidazole fiber Polymers 0.000 claims description 4
- 206010016807 Fluid retention Diseases 0.000 claims description 3
- 229920003235 aromatic polyamide Polymers 0.000 description 62
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- 239000010410 layer Substances 0.000 description 39
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- 239000000463 material Substances 0.000 description 28
- 230000004888 barrier function Effects 0.000 description 24
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- 238000009413 insulation Methods 0.000 description 16
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- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 description 9
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- 239000002131 composite material Substances 0.000 description 6
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- 229920000784 Nomex Polymers 0.000 description 5
- 230000008642 heat stress Effects 0.000 description 5
- -1 i.e. Substances 0.000 description 5
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- AYEKOFBPNLCAJY-UHFFFAOYSA-O thiamine pyrophosphate Chemical compound CC1=C(CCOP(O)(=O)OP(O)(O)=O)SC=[N+]1CC1=CN=C(C)N=C1N AYEKOFBPNLCAJY-UHFFFAOYSA-O 0.000 description 5
- 230000002209 hydrophobic effect Effects 0.000 description 4
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- 229920002994 synthetic fiber Polymers 0.000 description 2
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- OKTJSMMVPCPJKN-UHFFFAOYSA-N Carbon Chemical compound [C] OKTJSMMVPCPJKN-UHFFFAOYSA-N 0.000 description 1
- 206010019332 Heat exhaustion Diseases 0.000 description 1
- 206010020772 Hypertension Diseases 0.000 description 1
- 229920002821 Modacrylic Polymers 0.000 description 1
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- 229920006232 basofil Polymers 0.000 description 1
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- 239000004814 polyurethane Substances 0.000 description 1
- 238000009738 saturating Methods 0.000 description 1
- 239000002356 single layer Substances 0.000 description 1
- 239000002759 woven fabric Substances 0.000 description 1
Images
Classifications
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- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T442/00—Fabric [woven, knitted, or nonwoven textile or cloth, etc.]
- Y10T442/60—Nonwoven fabric [i.e., nonwoven strand or fiber material]
- Y10T442/696—Including strand or fiber material which is stated to have specific attributes [e.g., heat or fire resistance, chemical or solvent resistance, high absorption for aqueous compositions, water solubility, heat shrinkability, etc.]
Definitions
- the instant invention is directed to a thermal liner for use in, for example, protective garments.
- Protective garments are now well known for many and varied uses, such as suits for industrial workers, firefighters, wildlands firefighters, race car drivers, airplane pilots, and military personnel. Garments include not only complete, full body suits, but also individual garments such as trousers, jackets, gloves, boots, hats, head coverings, masks, etc. Generally, protective garments are designed to shield a wearer from a variety of environmental hazards. Firefighter garments are representative of such protective garments.
- Firefighter garments are designed primarily to prevent the firefighter from sustaining serious burns.
- a second significant threat to firefighters is heat stress. More firefighter deaths occur in the United States each year due to heat stress related conditions than due to burns. Heat stress related conditions include elevated body core temperature leading to heat prostration, increased blood pressure, heatstroke, and sometimes heart attack. As this second threat has become recognized, the fire service community has attempted to modify and improve turnout gear to minimize its contribution to heat stress.
- turnout gear includes a coat and overalls.
- Turnout gear typically comprises three layers: an outer shell, a moisture barrier, and a thermal barrier.
- the outer shell layer is usually a woven fabric made from flame resistant fibers and is considered the firefighter's first line of defense. Not only should it resist flame, but it needs to be tough and durable so as not to be torn, unduly abraded, or snagged during normal firefighting activities.
- the moisture barrier layer while also flame resistant, is provided to prevent water from penetrating and saturating the turnout gear. Excess moisture from the environment would laden the firefighter with extra weight and therefore increase their load. Such an increase in load is likely to increase the possibility of heat stress.
- the thermal barrier liner is also flame resistant and offers the bulk of the thermal protection afforded by the ensemble.
- a traditional thermal barrier liner includes an insulation layer of flame resistant fibers quilted to a lightweight woven face cloth also made of flame resistant fibers.
- a material commonly used as a component in the thermal barrier, and often regarded as an industry standard, is known as E89® from DuPont of Richmond, VA.
- E89 is a spunlaced nonwoven material consisting of NOMEX® (meta-aramid) staple or KEVLAR® (para-aramid) staple or a combination of both, Technical Guide for NOMEX® Brand Fiber, H-52720 Revised July 2001 by DuPont, Richmond, VA, page 3 .
- Nonwovens used in thermal layers have been suggested and they are disclosed in US Patents 4937136 , 5136723 , 5236769 , 6430754 , 6743498 , 7676855 , and US Publication 2002/0069453 .
- US4937136 teaches an inner thermal liner made with a nonwoven fabric of a blend of wool and a synthetic fiber capable of high temperature performance.
- the synthetic fibers include, among others, NOMEX, KEVLAR, and polybenzimidazole (PBI).
- US5136723 teaches an inner thermal barrier made with a mesh (apertured) fabric of NOMEX or KEVLAR having a basis weight of about 2 osy (ounces per square yard) or 67.8 gsm (grams per square meter). This mesh fabric is believed to be E89.
- US5236769 teaches textile layer of a nonwoven made with 100% aramids, mixtures of 30-50% wool and heat stable fiber, such as PBI. This nonwoven has a basis weight of 200 gsm (5.9 osy) at a thickness of 4 mm.
- US2007/0137012 is directed to a thermally protective fabric including a composition of inherently flame resistant fibers, and interstices having insulating pockets of air.
- US6407019 is directed to, among other things, an insulating lining made of at least a two ply nonwoven where each nonwoven ply has a basis weight of 80 gsm.
- WO 01/66193 discloses, among other things, a thermal liner made of a nonwoven of aramid of PBI materials.
- US6430754 teaches a second layer of insulating material of 50.8 gsm (1.5 osy) E89 or a spunlaced nonwoven of a blend of aramid and PBI fibers. US6430754 also teaches an alternate embodiment where the thermal barrier has a first layer of 78.0 gsm (2.3 osy) E89 (spunlaced nonwoven) and a second layer of 50.8 gsm (1.5 osy) E89 (spunlaced nonwoven).
- US6743498 teaches an insulating barrier of a perforated nonwoven having a basis weight in the range of 100-200 gsm and made from a variety of thermostable fiber including, among others, aramids and PBI.
- US767855 teaches an insulation layer of a nonwoven made of, among other things, aramids or melamines (but no PBI), the nonwoven maybe hydroentangled, and the basis weight of the nonwoven may be in the range of 25.4-271.2 gsm (0.75-8 osy). In the exemplary examples, the nonwoven is 84.8 gsm (2.5 osy) and made of 50% BASOFIL® melamine/25% meta-aramid/25% para-aramid.
- US Publication 2002/0069453 teaches the insulation layer comprising a blend of inherently hydrophobic fibers and non-hydrophobic, flame resistant fibers.
- the hydrophobic fibers include polytetrafluoroethylene (PTFE) fibers.
- the non-hydrophobic fibers include aramid fibers, PBI fibers, polybenzoxazole (PBO) fibers, melamine fibers, and blends thereof.
- the present invention provides a thermal liner for protective apparel comprising: a nonwoven having 15-30 wt % of a polybenzimidazole fiber, the remaining balance being an aramid fiber, the nonwoven excluding wool and cellulosic fibers, and having a thickness less than 3 mm and a basis weight of less than 2.9 osy (100 gsm).
- the protective apparel is a firefighter's turnout gear.
- the nonwoven for use in the thermal liner for example for use in a protective apparel, includes 15-30 wt % of the polybenzimidazole fiber as a first inherently heat resistant fiber, and a balance of aramid fiber as a second heat resistant fiber.
- the nonwoven excludes wool and has a thickness less than 3 mm and a basis weight of less than 100 gsm (2.9 osy).
- the thermal liner for protective apparel includes a nonwoven including an inherently flame resistant fiber and fibers being inherently resistant to moisture absorption.
- the inherently flame resistant fiber is different from said inherently resistant to moisture absorption fiber.
- the nonwoven has an equivalent or better thermal protective performance (TPP) and a lower basis weight than an industry standard nonwoven consisting of a nonwoven of para-aramids or meta-aramids or a blend of both.
- the first inherently heat resistant fiber and the second heat resistant fiber have a water retention of less than 15%.
- said nonwoven is a spunlaced and an apertured nonwoven.
- the thermal liner further comprises a facing fabric affixed to said nonwoven.
- the thermal liner further comprises multiple nonwovens.
- the present inventions provides a protective garment comprising a nonwoven thermal liner according to any of the examples described above.
- protective garment 10 is the jacket of a firefigther's turnout suit. It is understood, however, that the invention is not limited to firefighter's turnout gear. The invention may be used in other types of protective gear, as will be apparent to those of ordinary skill.
- Such other types of protective suits include, but are not limited to, suits for industrial workers (including, for example, arc flash apparel), wildlands firefighters, race car drivers, airplane pilots, military personnel, and the like.
- the protective garment 10 may have a multi-layer construction that includes an outer shell 20, a moisture barrier 40, and a thermal liner 60.
- the outer shell 20 is typically constructed of a flame and abrasion resistant material that comprises flame resistant fibers made of, for example, aramid (meta- and/or para-aramid), polybenzimidazole (PBI), polybenzoxazole (PBO), melamine, or the like, and blends thereof.
- the outer shell 20 may be treated with a water-resistant finish (for example, a perfluorohydrocarbon) to prevent or reduce water absorption from the outside environment.
- the weight of the outer shell material may be within the range of about 203.4-271.2 gsm, i.e. 6-8 ounces per square yard (osy).
- the moisture barrier 40 may be constructed of a non-woven or woven flame resistant fabric 42 comprising flame resistant fibers made of, for example, aramid (meta- and/or para-aramid), polybenzimidazole (PBI), polybenzoxazole (PBO), melamine, or the like, and blends thereof.
- the moisture barrier 40 may be laminated with a water-impermeable layer 44 of material such as, for instance, a layer of polytetrafluoroethylene (PTFE) or polyurethane (PU). When such an impermeable layer 44 is provided, it usually is provided on the moisture barrier 40, so as to face the thermal liner 60.
- the weight of the moisture barrier material is typically within the range about 135.6-203.4 gsm (4-6 osy).
- the thermal liner 60 may, optionally, include both an insulation layer 62 and a facecloth layer 64, which may be quilted together. In alternative embodiments, however, the insulation layer 62 alone may be used.
- the insulation layer 62 is discussed in greater detail below.
- the facecloth layer 64 may be constructed of woven material comprising flame resistant fibers made of, for example, aramid (meta-aramid or para-aramid), polybenzimidazole (PBI), polybenzoxazole (PBO), melamine, flame resistant (FR) cellulosics, modacrylic, carbon, or the like, and blends thereof.
- the facecloth layer 64 may be, optionally, finished with a hydrophilic finish that draws perspiration off of the firefighter's body, if desired.
- the weight of the facecloth layer material is normally in the range of about 33.9-203.4 gsm (1-6 osy).
- the insulation layer 62 comprises a nonwoven material that comprises a plurality of flame resistant fibers, discussed in greater detail below.
- the insulation layer 62 may comprise a single layer of nonwoven, or two layers of nonwoven, or multiple layers of nonwoven. In one embodiment, the insulation layer has two layers of nonwoven material, and each of these layers may have a different basis weight.
- the nonwoven material may be a weight range of about 25.4-271.2 gsm (0.75-8 osy). In one embodiment, the nonwoven material may be in a weight range of about 39.9-101.7 gsm (1.0-3.0 osy). In another embodiment, the nonwoven material may be in a weight range of 40.7-84.8 gsm (1.2-2.5 osy).
- the nonwoven material may be in a weight range of 40.7-67.8 gsm (1.2-2.0 osy).
- the insulation layer may comprise two nonwoven layer, one layer having a basis weight of about 47.5 gsm (1.4 osy) and the other layer having a basis weight of about 61.0 gsm (1.8 osy).
- the nonwoven material may have a thickness of less than 2 mm. In another embodiment, the nonwoven material may have a thickness of less than 1 mm. The nonwoven material, in all embodiments, should have a minimum thickness of 0.25 mm. In still another embodiment, the nonwoven material may have a thickness in the range of about 0.75-1.25 mm.
- the nonwoven material may be made by any nonwoven process. Such processes include, but are not limited to, wet laid, air laid, carding, felting, needlepunching, and hydroentangling (spunlaced). In one embodiment, the nonwoven may be spunlaced.
- the nonwoven material may be flat (i.e., without apertures), apertured (see US5136723 ), dimpled (see US7676855 ), or a combination of any of the foregoing.
- the nonwoven may comprise a plurality of flame resistant fibers.
- the nonwoven may exclude any wool and/or cellulosic fibers and/or natural fibers (i.e., any non-synthetic or non-man-made fibers).
- the nonwoven may be characterized has having an equivalent or better thermal protective performance (TPP per NFPA 1971 (2007)) and a lower basis weight than an industry standard nonwoven consisting of a nonwoven of para-aramids or meta-aramids or a blend of both, for example - E89.
- the flame resistant fibers may also be characterized as non-water absorbing fibers.
- Non-water absorbing fiber does not refer to the moisture regain of the fiber.
- Moisture regain refers to percentage of atmospheric moisture in a textile material brought into equilibrium with a standard atmosphere after partial drying, calculated as a percentage of the moisture-free weight.
- non-water absorbing fiber refers to the fibers ability, when placed in contact with liquid water, to swell, absorb, and retain that water.
- the water absorbency of fibers may be measured according to ASTM D2402 (2012). The maximum water retention that may be tolerated is less than 15%.
- the first inherently heat resistant fiber of the nonwoven material is selected from the group consisting of polybenzimidazoles.
- the second heat resistant fiber of the nonwoven material is selected from the group of aramids (meta- and/or para-aramids).
- the full composite refers turnout gear with an outer shell, moisture barrier, and a thermal liner.
- the outer shell was PBI MATRIX® available from Safety Components, Inc of Greenville, SC.
- the moisture barrier was CROSSTECH 2C available from W.L. Gore & Associates of Elkton, MD.
- the thermal barrier was unquilted and made with a NOMEX face cloth and the insulation layers set forth in TABLE 2. The first two listed materials are existing industry standard constructions and the remaining are examples of the instant invention.
- TABLE 3A-D there is shown several full composite comparisons of the instant invention to various industry standard full composites.
- the full composite refers turnout gear with an outer shell, moisture barrier, and a thermal liner.
- the outer shell was varied as indicated.
- the moisture barrier was varied as indicated.
- the thermal barrier was quilted and varied as indicated.
- TABLE 3A Outer Shell PBI MATRIX - Safety Components, Inc, Greenville, SC. Moisture barrier - CROSSTECH Black, W.L. Gore & Associates, Elkton, MD.
- Thermal Liner Fiber Blend Insulation Layers TPP 3 TPP gsm / osy Glide Araflo 1 33 wt%p-aramid/ 50.9 gsm, 1.5osy apertured 38.9 65.4 / 1.93 67% m-aramid 78.0 gsm, 2.3osy flat Glide E89 1 33 wt%p-aramid/ 50.9 gsm, 1.5osy flat 37.6 63.4 / 1.87 67% m-aramid 78.0 gsm, 2.3osy flat Caldura SL2 2 33 wt%p-aramid/ 50.9 gsm, 1.5osy flat 37.6 64.4 / 1.90 67% m-aramid 78.0 gsm, 2.3osy flat Quantum 3D 2 33 wt%p-aramid/ 50.9 gsm, 1.5osy flat 41.8 71.2 / 2.10 67% m-aramid 78.0 gsm, 2.3osy
- Thermal Liner Fiber Blend Insulation Layers TPP 3 TPP gsm / osy Caldura SL2 1 33 wt%p-aramid/ 50.9 gsm, 1.5osy flat 36.4 65.5 /1.93 67% m-aramid 78.0 gsm, 2.3osy flat Glide 2 20 wt% PBI/ 47.5 gsm, 1.4osy apertured 39.7 68.8 / 2.03 w/invention 80% m-aramid 61.0 gsm, 1.8osy apertured Apertured: spunlaced nonwoven with apertures, see for example US513723 . Flat: spunlaced nonwoven without apertures. 1 Available from TenCate, Union City, GA.
- Thermal Liner Fiber Blend Insulation Layers TPP 3 TPP gsm / osy Caldura SL2 1 33 wt%p-aramid/ 50.0 gsm, 1.5osy flat 38.2 66.8 / 1.97 67% m-aramid 78.0 gsm, 2.3osy flat Quantum 3D 1 33 wt%p-aramid/ 50.0 gsm, 1.5osy flat 41.3 67.8 / 2.00 67% m-aramid 78.0 gsm, 2.3osy dimpled Glide 2 20 wt% PBI/ 47.5 gsm, 1.4osy apertured 40.3 68.8 / 2.03 w/invention 80% m-aramid 61.0 gsm, 1.8osy apertured Apertured: spunlaced nonwoven with apertures, see for example US513723 .
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- Health & Medical Sciences (AREA)
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Description
- The instant invention is directed to a thermal liner for use in, for example, protective garments.
- Protective garments are now well known for many and varied uses, such as suits for industrial workers, firefighters, wildlands firefighters, race car drivers, airplane pilots, and military personnel. Garments include not only complete, full body suits, but also individual garments such as trousers, jackets, gloves, boots, hats, head coverings, masks, etc. Generally, protective garments are designed to shield a wearer from a variety of environmental hazards. Firefighter garments are representative of such protective garments.
- Firefighter garments, generally known as turnout gear, are designed primarily to prevent the firefighter from sustaining serious burns. A second significant threat to firefighters is heat stress. More firefighter deaths occur in the United States each year due to heat stress related conditions than due to burns. Heat stress related conditions include elevated body core temperature leading to heat prostration, increased blood pressure, heatstroke, and sometimes heart attack. As this second threat has become recognized, the fire service community has attempted to modify and improve turnout gear to minimize its contribution to heat stress.
- Generally, turnout gear includes a coat and overalls. Turnout gear typically comprises three layers: an outer shell, a moisture barrier, and a thermal barrier. The outer shell layer is usually a woven fabric made from flame resistant fibers and is considered the firefighter's first line of defense. Not only should it resist flame, but it needs to be tough and durable so as not to be torn, unduly abraded, or snagged during normal firefighting activities.
- The moisture barrier layer, while also flame resistant, is provided to prevent water from penetrating and saturating the turnout gear. Excess moisture from the environment would laden the firefighter with extra weight and therefore increase their load. Such an increase in load is likely to increase the possibility of heat stress.
- The thermal barrier liner is also flame resistant and offers the bulk of the thermal protection afforded by the ensemble. A traditional thermal barrier liner includes an insulation layer of flame resistant fibers quilted to a lightweight woven face cloth also made of flame resistant fibers. A material commonly used as a component in the thermal barrier, and often regarded as an industry standard, is known as E89® from DuPont of Richmond, VA. E89 is a spunlaced nonwoven material consisting of NOMEX® (meta-aramid) staple or KEVLAR® (para-aramid) staple or a combination of both, Technical Guide for NOMEX® Brand Fiber, H-52720 Revised July 2001 by DuPont, Richmond, VA, page 3.
- While E89 is an excellent material, there is a need to find better materials, i.e., materials with the same or better thermal protection and lower weights.
- Nonwovens used in thermal layers have been suggested and they are disclosed in
US Patents 4937136 ,5136723 ,5236769 ,6430754 ,6743498 ,7676855 , andUS Publication 2002/0069453 . -
US4937136 teaches an inner thermal liner made with a nonwoven fabric of a blend of wool and a synthetic fiber capable of high temperature performance. The synthetic fibers include, among others, NOMEX, KEVLAR, and polybenzimidazole (PBI). -
US5136723 teaches an inner thermal barrier made with a mesh (apertured) fabric of NOMEX or KEVLAR having a basis weight of about 2 osy (ounces per square yard) or 67.8 gsm (grams per square meter). This mesh fabric is believed to be E89. -
US5236769 teaches textile layer of a nonwoven made with 100% aramids, mixtures of 30-50% wool and heat stable fiber, such as PBI. This nonwoven has a basis weight of 200 gsm (5.9 osy) at a thickness of 4 mm. -
US2007/0137012 is directed to a thermally protective fabric including a composition of inherently flame resistant fibers, and interstices having insulating pockets of air. -
US6407019 is directed to, among other things, an insulating lining made of at least a two ply nonwoven where each nonwoven ply has a basis weight of 80 gsm. -
WO 01/66193 -
US6430754 teaches a second layer of insulating material of 50.8 gsm (1.5 osy) E89 or a spunlaced nonwoven of a blend of aramid and PBI fibers.US6430754 also teaches an alternate embodiment where the thermal barrier has a first layer of 78.0 gsm (2.3 osy) E89 (spunlaced nonwoven) and a second layer of 50.8 gsm (1.5 osy) E89 (spunlaced nonwoven). -
US6743498 teaches an insulating barrier of a perforated nonwoven having a basis weight in the range of 100-200 gsm and made from a variety of thermostable fiber including, among others, aramids and PBI. -
US767855 teaches an insulation layer of a nonwoven made of, among other things, aramids or melamines (but no PBI), the nonwoven maybe hydroentangled, and the basis weight of the nonwoven may be in the range of 25.4-271.2 gsm (0.75-8 osy). In the exemplary examples, the nonwoven is 84.8 gsm (2.5 osy) and made of 50% BASOFIL® melamine/25% meta-aramid/25% para-aramid. -
US Publication 2002/0069453 teaches the insulation layer comprising a blend of inherently hydrophobic fibers and non-hydrophobic, flame resistant fibers. The hydrophobic fibers include polytetrafluoroethylene (PTFE) fibers. The non-hydrophobic fibers include aramid fibers, PBI fibers, polybenzoxazole (PBO) fibers, melamine fibers, and blends thereof. - The present invention provides a thermal liner for protective apparel comprising: a nonwoven having 15-30 wt % of a polybenzimidazole fiber, the remaining balance being an aramid fiber, the nonwoven excluding wool and cellulosic fibers, and having a thickness less than 3 mm and a basis weight of less than 2.9 osy (100 gsm). Advantageously the protective apparel is a firefighter's turnout gear.
- In one embodiment the nonwoven for use in the thermal liner, for example for use ina protective apparel, includes 15-30 wt % of the polybenzimidazole fiber as a first inherently heat resistant fiber, and a balance of aramid fiber as a second heat resistant fiber. The nonwoven excludes wool and has a thickness less than 3 mm and a basis weight of less than 100 gsm (2.9 osy). In another embodiment, the thermal liner for protective apparel includes a nonwoven including an inherently flame resistant fiber and fibers being inherently resistant to moisture absorption. The inherently flame resistant fiber is different from said inherently resistant to moisture absorption fiber. The nonwoven has an equivalent or better thermal protective performance (TPP) and a lower basis weight than an industry standard nonwoven consisting of a nonwoven of para-aramids or meta-aramids or a blend of both.
- In one example of the thermal liner the first inherently heat resistant fiber and the second heat resistant fiber have a water retention of less than 15%.
- In one example of the thermal liner said nonwoven is a spunlaced and an apertured nonwoven.
- In still another example, the thermal liner further comprises a facing fabric affixed to said nonwoven.
- In yet another example, the thermal liner further comprises multiple nonwovens.
- According to another aspect the present inventions provides a protective garment comprising a nonwoven thermal liner according to any of the examples described above.
- For the purpose of illustrating the invention, there is represented in the figures data from various embodiments of the invention; it being understood, however, that this invention is not limited to the data shown and that this data is not necessarily been optimized, but instead only indicates the possibilities for the inventive materials.
-
Figure 1 is an illustration of a protective garment, parts broken away. -
Figure 2 is an exploded view of the layers of the protective garment shown inFigure 1 . - Referring to the Figures, wherein like numerals refer to like elements, there is shown in
Figure 1 , aprotective garment 10. Specifically,protective garment 10 is the jacket of a firefigther's turnout suit. It is understood, however, that the invention is not limited to firefighter's turnout gear. The invention may be used in other types of protective gear, as will be apparent to those of ordinary skill. Such other types of protective suits include, but are not limited to, suits for industrial workers (including, for example, arc flash apparel), wildlands firefighters, race car drivers, airplane pilots, military personnel, and the like. - As indicated in
Figures 1 and 2 , theprotective garment 10 may have a multi-layer construction that includes anouter shell 20, amoisture barrier 40, and athermal liner 60. Theouter shell 20 is typically constructed of a flame and abrasion resistant material that comprises flame resistant fibers made of, for example, aramid (meta- and/or para-aramid), polybenzimidazole (PBI), polybenzoxazole (PBO), melamine, or the like, and blends thereof. Theouter shell 20 may be treated with a water-resistant finish (for example, a perfluorohydrocarbon) to prevent or reduce water absorption from the outside environment. The weight of the outer shell material may be within the range of about 203.4-271.2 gsm, i.e. 6-8 ounces per square yard (osy). - The
moisture barrier 40 may be constructed of a non-woven or woven flameresistant fabric 42 comprising flame resistant fibers made of, for example, aramid (meta- and/or para-aramid), polybenzimidazole (PBI), polybenzoxazole (PBO), melamine, or the like, and blends thereof. Themoisture barrier 40 may be laminated with a water-impermeable layer 44 of material such as, for instance, a layer of polytetrafluoroethylene (PTFE) or polyurethane (PU). When such animpermeable layer 44 is provided, it usually is provided on themoisture barrier 40, so as to face thethermal liner 60. The weight of the moisture barrier material is typically within the range about 135.6-203.4 gsm (4-6 osy). - The
thermal liner 60 may, optionally, include both aninsulation layer 62 and afacecloth layer 64, which may be quilted together. In alternative embodiments, however, theinsulation layer 62 alone may be used. Theinsulation layer 62 is discussed in greater detail below. When it is used, thefacecloth layer 64 may be constructed of woven material comprising flame resistant fibers made of, for example, aramid (meta-aramid or para-aramid), polybenzimidazole (PBI), polybenzoxazole (PBO), melamine, flame resistant (FR) cellulosics, modacrylic, carbon, or the like, and blends thereof. Thefacecloth layer 64 may be, optionally, finished with a hydrophilic finish that draws perspiration off of the firefighter's body, if desired. The weight of the facecloth layer material is normally in the range of about 33.9-203.4 gsm (1-6 osy). - The
insulation layer 62 comprises a nonwoven material that comprises a plurality of flame resistant fibers, discussed in greater detail below. Theinsulation layer 62 may comprise a single layer of nonwoven, or two layers of nonwoven, or multiple layers of nonwoven. In one embodiment, the insulation layer has two layers of nonwoven material, and each of these layers may have a different basis weight. The nonwoven material may be a weight range of about 25.4-271.2 gsm (0.75-8 osy). In one embodiment, the nonwoven material may be in a weight range of about 39.9-101.7 gsm (1.0-3.0 osy). In another embodiment, the nonwoven material may be in a weight range of 40.7-84.8 gsm (1.2-2.5 osy). In yet another embodiment, the nonwoven material may be in a weight range of 40.7-67.8 gsm (1.2-2.0 osy). In still another embodiment, the insulation layer may comprise two nonwoven layer, one layer having a basis weight of about 47.5 gsm (1.4 osy) and the other layer having a basis weight of about 61.0 gsm (1.8 osy). In one embodiment, the nonwoven material may have a thickness of less than 2 mm. In another embodiment, the nonwoven material may have a thickness of less than 1 mm. The nonwoven material, in all embodiments, should have a minimum thickness of 0.25 mm. In still another embodiment, the nonwoven material may have a thickness in the range of about 0.75-1.25 mm. The nonwoven material may be made by any nonwoven process. Such processes include, but are not limited to, wet laid, air laid, carding, felting, needlepunching, and hydroentangling (spunlaced). In one embodiment, the nonwoven may be spunlaced. The nonwoven material may be flat (i.e., without apertures), apertured (seeUS5136723 ), dimpled (seeUS7676855 ), or a combination of any of the foregoing. - The nonwoven may comprise a plurality of flame resistant fibers. The nonwoven may exclude any wool and/or cellulosic fibers and/or natural fibers (i.e., any non-synthetic or non-man-made fibers). The nonwoven may be characterized has having an equivalent or better thermal protective performance (TPP per NFPA 1971 (2007)) and a lower basis weight than an industry standard nonwoven consisting of a nonwoven of para-aramids or meta-aramids or a blend of both, for example - E89.
- In one embodiment, the flame resistant fibers may also be characterized as non-water absorbing fibers. Non-water absorbing fiber does not refer to the moisture regain of the fiber. Moisture regain, as used herein, refers to percentage of atmospheric moisture in a textile material brought into equilibrium with a standard atmosphere after partial drying, calculated as a percentage of the moisture-free weight. Instead, non-water absorbing fiber refers to the fibers ability, when placed in contact with liquid water, to swell, absorb, and retain that water. The water absorbency of fibers may be measured according to ASTM D2402 (2012). The maximum water retention that may be tolerated is less than 15%.
- The first inherently heat resistant fiber of the nonwoven material is selected from the group consisting of polybenzimidazoles.
- The second heat resistant fiber of the nonwoven material is selected from the group of aramids (meta- and/or para-aramids).
- The following examples further illustrate the invention; it being understood, however, that this invention is not limited to the precise formulations set forth.
- In Table 1, there are shown several representative embodiments of the instant invention compared to the certain industry standard materials. These embodiments illustrate a range of thickness and basis weights that may be useful in the manufacture of turnout gear. Fiber blends A-B represent the inventive embodiments and fiber blend C represents an industry standard material.
TABLE 1 Fiber Blend Structure Basis Weight Thickness (mm) (mm/gsm) · 100 (gsm) [osy] A Apertured 56.9 [1.68] 0.89 1.56 A Apertured 66.5 [1.96] 0.97 1.46 A Apertured 84.6 [2.50] 1.10 1.30 B1 Apertured 48.1 [1.42] 0.74 1.54 B1 Apertured 62.0 [1.83] 0.93 1.50 B Apertured 77.7 [2.29] 1.07 1.38 B Apertured 85.0 [2.50] 1.19 1.40 C2 Flat 50.0 [1.47] 0.70 1.40 C3 Flat 80.0 [2.36] 0.87 1.09 C Dimpled 80.0 [2.36] 1.22 1.53 A: 47 wt% m-aramid/33% p-aramid/20% PBI
B: 80 wt% m-aramid/20% PBI
C: 67 wt% m-aramid/33% p-aramid
Apertured: spunlaced nonwoven with apertures, see for exampleUS513723 .
Flat: spunlaced nonwoven without apertures.
Dimples: spunlaced nonwoven without apertures but having dimples, see for exampleUS7676855 . Also referred to in the industry as '3D.'
Conversion: (gsm/33.9)=osy.
1Exemplary embodiment.
2Industry standard - 50.1.gsm (5osy) spunlace.
3Industry standard - 78.0 gsm (2.3osy) spunlace. - In TABLE 2, there are shown several full composite comparisons of the instant invention industry standards. The full composite refers turnout gear with an outer shell, moisture barrier, and a thermal liner. The outer shell was PBI MATRIX® available from Safety Components, Inc of Greenville, SC. The moisture barrier was CROSSTECH 2C available from W.L. Gore & Associates of Elkton, MD. The thermal barrier was unquilted and made with a NOMEX face cloth and the insulation layers set forth in TABLE 2. The first two listed materials are existing industry standard constructions and the remaining are examples of the instant invention.
TABLE 2 Fiber Blend Insulation Layers Full Composite basis Weight TPP4 TPP gsm/osy gsm (osy) 33 wt%p-aramid/ 50.9 gsm, 1.5osy flat 677.7 (19.99) 35.5 60.3/1.78 67% m-aramid1 78.0 gsm, 2.3osy flat 33 wt%p-aramid/ 50.9 gsm, 1.5osy flat 661.0 (19.55) 36.4 63.0/1.86 67% m-aramid2 78.0 gsm, 2.3osy dimpled 20 wt% PBI/ 47.5 gsm, 1.4osy apertured 640.4 (18.89) 36.2 65.0/1.92 80% m-aramid3 61.0 gsm, 1.8osy apertured 47wt% m-aramid/ 57.6 gsm, 1.7osy apertured 642.4 (18.95) 34.7 62.0/1.83 33% p-aramid/20% PBI 57.6 gsm, 1.7osy apertured 47wt% m-aramid/ 67.8 gsm, 2.0osy apertured 653.2 (19.27) 36.7 64.4/1.90 33% p-aramid/20% PBI 57.6 gsm, 1.7osy apertured 20 wt% PBI/ 47.5 gsm, 1.4osy apertured 657.3 (19.39) 37.2 65.0/1.92 80% m-aramid 78.0 gsm, 2.3osy apertured 20 wt% PBI/ 61.0 gsm, 1.8osy apertured 658.0 (19.41) 36.6 64.0/1.89 80% m-aramid 61.0 gsm, 1.8osy apertured Apertured: spunlaced nonwoven with apertures, see for example US513723 .
Flat: spunlaced nonwoven without apertures.
Dimples: spunlaced nonwoven without apertures but having dimples, see for exampleUS7676855 .
1Industry standard
2Industry standard
3Exemplary embodiment
4TPP - Thermal Protection Performance per NFPA1971 (2007). - In TABLE 3A-D, there is shown several full composite comparisons of the instant invention to various industry standard full composites. The full composite refers turnout gear with an outer shell, moisture barrier, and a thermal liner. The outer shell was varied as indicated. The moisture barrier was varied as indicated. The thermal barrier was quilted and varied as indicated.
TABLE 3A Outer Shell: PBI MATRIX - Safety Components, Inc, Greenville, SC. Moisture barrier - CROSSTECH Black, W.L. Gore & Associates, Elkton, MD. Thermal Liner Fiber Blend Insulation Layers TPP3 TPP gsm / osy Glide Araflo1 33 wt%p-aramid/ 50.9 gsm, 1.5osy apertured 38.9 65.4 / 1.93 67% m-aramid 78.0 gsm, 2.3osy flat Glide E891 33 wt%p-aramid/ 50.9 gsm, 1.5osy flat 37.6 63.4 / 1.87 67% m-aramid 78.0 gsm, 2.3osy flat Caldura SL22 33 wt%p-aramid/ 50.9 gsm, 1.5osy flat 37.6 64.4 / 1.90 67% m-aramid 78.0 gsm, 2.3osy flat Quantum 3D2 33 wt%p-aramid/ 50.9 gsm, 1.5osy flat 41.8 71.2 / 2.10 67% m-aramid 78.0 gsm, 2.3osy dimpled Glide 120 wt% PBI/ 47.5 gsm, 1.4osy apertured 39.3 64.4 / 1.90 w/invention 80% m-aramid 61.0 gsm, 1.8osy apertured Apertured: spunlaced nonwoven with apertures, see for example US513723 .
Flat: spunlaced nonwoven without apertures.
Dimples: spunlaced nonwoven without apertures but having dimples, see for exampleUS7676855 .
1Available from Safety Components, Inc, Greenville, SC.
2Available from TenCate, Union City, GA.
3TPP - Thermal Protection Performance per NFPA1971 (2007).TABLE 3B Outer Shell: PBI MAX - Safety Components, Inc, Greenville, SC. Moisture barrier - CROSSTECH Black, W.L. Gore & Associates, Elkton, MD Thermal Liner Fiber Blend Insulation Layers TPP3 TPP gsm / osy Glide Araflo1 33 wt%p-aramid/ 50.9 gsm, 1.5osy apertured 39.2 71.2 / 2.10 67% m-aramid 78.0 gsm, 2.3osy flat Glide E891 33 wt%p-aramid/ 50.9 gsm, 1.5osy flat 39.7 70.2 / 2.07 67% m-aramid 78.0 gsm, 2.3osy flat Quantum 3D2 33 wt%p-aramid/ 50.9 gsm, 1.5osy flat 42.2 73.2 / 2.16 67% m-aramid 78.0 gsm, 2.3osy dimpled Glide 120 wt% PBI/ 47.5 gsm, 1.4osy apertured 43.4 74.6 / 2.20 w/invention 80% m-aramid 61.0 gsm, 1.8osy apertured Apertured: spunlaced nonwoven with apertures, see for example US513723 .
Flat: spunlaced nonwoven without apertures.
Dimples: spunlaced nonwoven without apertures but having dimples, see for exampleUS7676855 .
1Available from Safety Components, Inc, Greenville, SC.
2Available from TenCate, Union City, GA.
3TPP - Thermal Protection Performance per NFPA1971 (2007).TABLE 3C Outer Shell: GEMINI - TenCate, Union City, GA. Moisture barrier - CROSSTECH Black, W.L. Gore & Associates, Elkton, MD. Thermal Liner Fiber Blend Insulation Layers TPP3 TPP gsm / osy Caldura SL21 33 wt%p-aramid/ 50.9 gsm, 1.5osy flat 36.4 65.5 /1.93 67% m-aramid 78.0 gsm, 2.3osy flat Glide 2 20 wt% PBI/ 47.5 gsm, 1.4osy apertured 39.7 68.8 / 2.03 w/invention 80% m-aramid 61.0 gsm, 1.8osy apertured Apertured: spunlaced nonwoven with apertures, see for example US513723 .
Flat: spunlaced nonwoven without apertures.
1Available from TenCate, Union City, GA.
2Available from Safety Components, Inc, Greenville, SC.
3TPP - Thermal Protection Performance per NFPA1971 (2007).TABLE 3D Outer Shell: GEMINI XT - TenCate, Union City, GA. Moisture barrier - CROSSTECH Black, W.L. Gore & Associates, Elkton, MD. Thermal Liner Fiber Blend Insulation Layers TPP3 TPP gsm / osy Caldura SL21 33 wt%p-aramid/ 50.0 gsm, 1.5osy flat 38.2 66.8 / 1.97 67% m-aramid 78.0 gsm, 2.3osy flat Quantum 3D1 33 wt%p-aramid/ 50.0 gsm, 1.5osy flat 41.3 67.8 / 2.00 67% m-aramid 78.0 gsm, 2.3osy dimpled Glide 220 wt% PBI/ 47.5 gsm, 1.4osy apertured 40.3 68.8 / 2.03 w/invention 80% m-aramid 61.0 gsm, 1.8osy apertured Apertured: spunlaced nonwoven with apertures, see for example US513723 .
Flat: spunlaced nonwoven without apertures.
Dimples: spunlaced nonwoven without apertures but having dimples, see for exampleUS7676855 .
1Available from TenCate, Union City, GA.
2Available from Safety Components, Inc, Greenville, SC.
3TPP - Thermal Protection Performance per NFPA1971 (2007).
Claims (8)
- A thermal liner (60) for protective apparel (10) comprising: a nonwoven (62) having
15-30 wt % of a polybenzimidazole fiber,
the remaining balance being an aramid fiber,
the nonwoven excluding wool and cellulosic fibers, and
having a thickness less than 3 mm and a basis weight of less than 2.9 osy (100 gsm). - The thermal liner (60) of claim 1, wherein the polybenzimidazole fiber is a first inherently heat resistant fiber and the aramid fiber is a second heat resistant fiber.
- The thermal liner (60) of claim 2, wherein the first inherently heat resistant fiber and the second heat resistant fiber have a water retention of less than 15%, as measured by ASTM D2402 (2012).
- The thermal liner (60) of any of claims 1 to 3, wherein the protective apparel (10) being a firefighter's turnout gear.
- The thermal liner (60) of any of claims 1 to 4, wherein said nonwoven (62) being a spunlaced and an apertured nonwoven.
- The thermal liner (60) of any of the preceding claims, further comprising a facing fabric (64) affixed to said nonwoven (62).
- The thermal liner (60) of any of the preceding claims, further comprising multiple nonwovens (62).
- A protective garment (10) comprising a thermal liner (60) according to any of the preceding claims 1 to 7.
Priority Applications (1)
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PL18201602T PL3479712T3 (en) | 2012-09-25 | 2013-09-03 | Thermal liner for protective garments |
Applications Claiming Priority (3)
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US13/626,179 US9409378B2 (en) | 2012-09-25 | 2012-09-25 | Thermal liner for protective garments |
EP13840310.0A EP2900097B1 (en) | 2012-09-25 | 2013-09-03 | Thermal liner for protective garments |
PCT/US2013/057773 WO2014051936A1 (en) | 2012-09-25 | 2013-09-03 | Thermal liner for protective garments |
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EP13840310.0A Division EP2900097B1 (en) | 2012-09-25 | 2013-09-03 | Thermal liner for protective garments |
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EP3479712A1 EP3479712A1 (en) | 2019-05-08 |
EP3479712B1 true EP3479712B1 (en) | 2020-10-21 |
Family
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EP13840310.0A Active EP2900097B1 (en) | 2012-09-25 | 2013-09-03 | Thermal liner for protective garments |
EP18201602.2A Active EP3479712B1 (en) | 2012-09-25 | 2013-09-03 | Thermal liner for protective garments |
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EP13840310.0A Active EP2900097B1 (en) | 2012-09-25 | 2013-09-03 | Thermal liner for protective garments |
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US (3) | US9409378B2 (en) |
EP (2) | EP2900097B1 (en) |
ES (2) | ES2860455T3 (en) |
PL (2) | PL2900097T3 (en) |
WO (1) | WO2014051936A1 (en) |
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DE102015004841A1 (en) * | 2015-04-15 | 2016-10-20 | Norafin Industries (Germany) Gmbh | Nonwoven fabric layer for heat protection textiles |
GB2538533A (en) * | 2015-05-20 | 2016-11-23 | Magnet Mouse Ltd | Improvements in shirts |
USD812857S1 (en) * | 2015-05-26 | 2018-03-20 | Clothing Arts, Ltd. | Jacket with safety pockets |
CN108601410B (en) * | 2016-01-13 | 2021-06-29 | 杜邦安全与建筑公司 | Improved thermal protective clothing |
CA3011354A1 (en) * | 2016-01-14 | 2017-07-20 | Southern Mills, Inc. | Improved flame resistant thermal liners and garments made with same |
US20170361567A1 (en) * | 2016-06-16 | 2017-12-21 | Honeywell International Inc. | Light weight textile structure for arc flash protection with minimum arc rating |
CN105962494B (en) * | 2016-06-30 | 2018-01-23 | 温州庄吉服饰有限公司 | The manufacture craft of Western-style clothes full hemp liner |
CA2993706C (en) * | 2017-02-02 | 2020-06-09 | Claude Barbeau | Protective interfaces for firefighter garments |
US20230085498A1 (en) * | 2021-09-01 | 2023-03-16 | Fire-Dex, Llc | Thermal liner |
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- 2013-09-03 ES ES18201602T patent/ES2860455T3/en active Active
- 2013-09-03 ES ES13840310T patent/ES2705528T3/en active Active
- 2013-09-03 WO PCT/US2013/057773 patent/WO2014051936A1/en active Application Filing
- 2013-09-03 PL PL18201602T patent/PL3479712T3/en unknown
- 2013-09-03 EP EP18201602.2A patent/EP3479712B1/en active Active
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2016
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Also Published As
Publication number | Publication date |
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US20140087129A1 (en) | 2014-03-27 |
US20160227858A1 (en) | 2016-08-11 |
ES2705528T3 (en) | 2019-03-25 |
PL2900097T3 (en) | 2019-03-29 |
EP2900097A4 (en) | 2016-06-01 |
PL3479712T3 (en) | 2021-06-28 |
US20220053859A1 (en) | 2022-02-24 |
EP3479712A1 (en) | 2019-05-08 |
EP2900097A1 (en) | 2015-08-05 |
ES2860455T3 (en) | 2021-10-05 |
EP2900097B1 (en) | 2018-10-24 |
US9409378B2 (en) | 2016-08-09 |
WO2014051936A1 (en) | 2014-04-03 |
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